KR20070001059A - Collapsible integrated pallet system - Google Patents

Abstract

The collapsible shipping pallet incorporates a substantially planar deck (12) with multiple stringers (14) removably attached to the bottom of the deck. Shouldered holes (22) arranged in linear spaced relation at predetermined stringer attachment locations on the deck engage resilient slotted pins (24) extending from a top edge each stringer. Multiple slats (16), each extending perpendicularly to the stringers and removably received in a relief on a bottom edge of each stringer are attached to the stringers also using resilient slotted pins. The stringers support triangular jaws (78, 80) inserted in triangular recesses (82) in an end portion of the stringer to receive and restrain pallet straps. An aperture (100) in the side of the stringer allows insertion of a slotted crank to tension the pallet straps. The deck incorporates slots (132) adapted to receive keys (134) to extend above the surface of the deck engaging receiving slots in a first layer of stacking boxes. ® KIPO & WIPO 2007

Description

Folding integrated pallet system {COLLAPSIBLE INTEGRATED PALLET SYSTEM}

FIELD OF THE INVENTION The present invention relates generally to goods transport pallets, and more particularly to folded pallets having molded parts for field assembly.

Most shipping pallets are wood construction with flanks or slats attached with screws or nails to wood reinforcement. Normally, the manufacture of the pallets is carried out at the place of shipment, and if the pallets are to be reused, lamination for the return of the empty pallets requires considerable volume. Wooden pallets are heavy and constitute a heavy burden for the return of void pallets while significantly increasing the shipping weight of goods stacked on the pallets. Alternative materials, such as metals and plastics, have been employed to increase the durability of the pallet configuration, but void shipping volumes leave significant problems for pallet reuse.

Laminating and retaining the loaded goods on an existing pallet is usually performed by stacking goods boxes on the pallet and securing the boxes by metal or plastic strapping. Fibreboard or wooden crates can slide against each other, thereby overturning the pallets loaded. To partially avoid this problem, interlocking box systems have been developed, such as those disclosed in US Pat. No. 5,497,939 and named containers with panel locks. However, a pallet system for integrating and fixing these containers was not available.

Thus, it is desirable that the pallet can be easily assembled from the folded state while promoting volume efficient empty loading. More preferably, the pallet is provided with a light weight material to reduce the folded and loaded shipping weight.

It is also desirable to incorporate the integrated fixed feature such that the pallet receives the interlocking box system.

The folding shipping pallet of the present invention incorporates a generally planar deck having a plurality of reinforcements detachably attached to the bottom of the deck. The deck incorporates shoulder holes arranged in a linearly spaced relationship at a given stiffener attachment location. The resilient slot pins extend from the top edge of each stiffener, each pin having an extended shank and head opposite the top edge of the stiffener. A cylindrical collar is inserted into each shoulder hole, and a flange extending from the body of the collar engages the shoulder of the hole. Each collar has a bore having a first diameter portion sized to receive the shank of the pin and a second diameter portion forming a step that engages the head to press the pin into the bore to secure the reinforcement to the deck.

Multiple slats, each extending perpendicular to the stiffener and detachably received in the relief on the lower edge of each stiffener, are also attached to the stiffener using elastic slot pins, one pin being the top of each slat relief in each stiffener. Suspended from the surface. Each pin has a shank opposite the upper surface of the relief and an extended head. The aforementioned flanged cylindrical collar is inserted into each shoulder hole in the slat to press the pin into the bore to secure the slat to the stiffener.

The stiffener incorporates triangular jaws inserted into a triangular recess in the end of the stiffener with slots for receiving and limiting the pallet straps. Holes in the sides of the stiffener allow the insertion of slot cranks to tension the pallet straps. The outer circumference of the deck incorporates a slot configured to receive a key for extending beyond the surface of the deck that engages the receiving slot within the first layer of the lamination box.

These and other features and advantages of the present invention will be better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings.

1 is a perspective view of a pallet side reinforcement and deck embodying the present invention.

FIG. 2 is a bottom perspective view of the pallet of FIG.

3 is an isometric view of one reinforcement from the pallet of FIG.

4A is a partial cross-sectional view showing the details of the reinforcement and the slat attachment pins and holes.

4B is a partial cross-sectional view of the deck showing details of a simplified embodiment of stiffener and slat attachments.

5 is an exploded isometric view of the pin and collar used to secure the reinforcement to the deck and the slats to the reinforcement.

6 is a detailed view of two ends of the reinforcement of FIG.

FIG. 7A is a top view of a reinforcement having a crank coupled to stiffen the strap, as shown in FIG.

FIG. 7B is a side view of the reinforcement having a crank coupled to stiffen the strap, as shown in FIG.

8 is an isometric view of a magnetic coupling box for use with the pallet system of the present invention.

Figure 9 is a partial perspective view of an assembled pallet incorporating the present invention loaded with the box of Figure 8;

10A is a front view of a pallet having two stacked boxes.

FIG. 10B is a detailed cross-sectional view illustrating the box engagement slot in the deck with the merged key taken along line 10b-10b in FIG. 10A.

Referring to the drawings, FIG. 1 shows a pallet 10 embodying the present invention. Deck 12 provides a load bearing surface for the pallet. Multiple reinforcements 14 are detachably attached to the bottom surface of the deck. The slat 16 is detachably attached to the bottom of the reinforcement as best shown in FIG. The slats are supported into recesses 18 in the bottom of the reinforcement. Cutouts 20 are provided in each reinforcement to accommodate the forklifts of the forklift for moving and lifting the assembled and loaded pallets.

As shown in Figure 1, the deck incorporates multiple attachment holes 22 for each stiffener. As shown in FIG. 3, each reinforcement has multiple elastic pins 24 extending from the top surface 26. Details of the holes and attachment pins for one embodiment are shown in FIG. 4A. Each hole has a shoulder 28 indented from the surface 30 of the deck and a collar bore 32 extending through the lower portion 34 of the deck. The pin on the reinforcement is received in the hole, and the collar 36 is inserted into the hole from the top of the deck by a flange 38 that engages the shoulder of the hole. The shank 40 on each pin is received in the pin bore 42, and the head 44 engages the step 46 in the bore of the collar. Each pin has a slot 48 that provides resiliency for compression of the head during insertion through the pin bore during assembly. At the base of the pin, the web 50 interconnects the sides of the pin body. Exemplary collars and pins are shown in more detail as an exploded view in FIG.

In the simplified embodiment shown in Fig. 4b, no collar is employed, and the hole in the deck directly receives the pin while the head of the pin engages the shoulder of the hole by appropriate re-dimensioning of the shoulder depth, Avoid exposing the pin head over the deck surface.

Returning to Figure 3, the slats 16 are attached to the reinforcement in a manner consistent with the attachment of the reinforcement to the deck. The pins 52 suspended from the reinforcement are received in the holes 54 in each slat. In the embodiment shown, the hole incorporates a collar bore 56 and a shoulder 58. The collar 60 with the flange 62 is received in the hole with the flange engaging the shoulder. Each collar has a pin bore 64 that receives the shank 66 of the pin and a step 68 that couples to the pin head 70. In the illustrated embodiment, with the pins securing the reinforcement to the deck, the pins securing the slats incorporate a slot 72 for elastic deformation of the head while being inserted into the collar.

By the deck hole and pin arrangement for the simplified embodiment shown in FIG. 4B, no collar for attachment of the slats was employed, and the holes in the slats were provided at the shoulders to avoid exposure of the pin head below the surface of the slats. By proper readjustment of the depth, the head of the pin engages the shoulder of the hole and receives the pin directly.

To provide a flat bottom for the pallet, the stiffener of the present embodiment shown incorporates a relief 76 into which each slat is inserted. The pins suspended on the stiffeners are generally centered in the relief to engage the slats, which are flat skid surfaces formed by the stiffeners and the slats. In order to accommodate the lifting of the pallet by the forklift, as described above, the fork cutout 20 is provided in the reinforcement at two points between the slat reliefs.

Integral strap tensioning and securing is performed within a pallet embodying the present invention as shown in FIGS. 6, 7A, and 7B. The reinforcement incorporates a pair of triangular jaws 78, 80 supported in the triangular cutout 82 in the end block 84 on the reinforcement. The cutout is connected to the end surface 86 of the block through slot 88. Straps inserted through the slots are frictionally engaged across the jaws. The withdrawal tension on the straps provides greater frictional engagement of the straps to press the jaws to the apex of the cutout to force the jaws together while preventing them from being pulled out.

The jaws are pressed into the cutouts by separation or ridge 90 on the surface of the cutout that engages one edge of the base 92 of the lower jaw 78. Tabs 94 on the lower jaws are received in cutout 96 on upper jaws 80 to couple the jaws to prevent separation or separate movement of one jaw.

Tension of the strap is performed by a crank 98 inserted through the hole 100 in the sidewall 102 of the stiffener. Strap 104 is coupled within slot 106 in the crank. Rotation of the crank winds the strap on itself for frictional engagement with the crank. Once the strap is fully tensioned, the retraction on the crank allows jaws to fully engage the strap, reduce strap friction on the crank, and allow the strap to be removed.

Several methods are employed to remove the strap when the shipment is complete. If the strap is disposable, the strap is simply cut off of the slot and the tail removed from the jaw by pulling the strap inward to release the jaw and allow removal. If the strap is reusable, the crank can be reinserted through the opening to engage the strap and tension to allow disjointing of the jaw that is subsequently removed by turning the jaw laterally from the triangular cutout. The tension on the crank is then released to allow the strap to retract from the slot. Finally, in some embodiments, additional holes are provided in the reinforcement adjacent the triangular cutouts and the strap slot extends through the side of the end block of the reinforcement. Flat surface pins driven through additional holes force lateral shifts of jaws and straps from cutouts and slots, respectively. The jaws are then removed from the strap and replaced in the cutout.

Another embodiment of the present invention employs a removable pin to accommodate breakage of the pin on the reinforcement. In one embodiment shown in FIG. 4A, the pin incorporates a thread 112 on the shank opposite the head. The thread is received in a thread bore 114 in the reinforcement. Slots in the pin allow the flat blade tool to be used for insertion or removal of the pin from the stiffener.

A pallet embodying the present invention is a self-laminated container, such as that disclosed in US Pat. No. 5,497,939, designated as a container with a panel lock, owned by the assignee of the present invention, and incorporated herein by reference as if fully set forth. Especially useful for As shown in FIG. 8, a container 120 having end plates 122, 124 and a folding panel 126 pressed by the end plates has laminated tabs 128 extending from the top surface of each end plate. Adopt. As shown in Fig. 9, the stacking tabs are engaged in receiving slots 130 in the end plates of the second container stacked on top of the first container.

As detailed in FIGS. 10A and 10B, the deck incorporates a key slot 132 positioned in a spaced apart relationship to receive the blade key 134, and then the blade key 134 is loaded on the deck. It is received in the receiving slot of the lower layer of the stacked container and thus prevents slipping or fluctuation on the pallet deck. For the embodiment shown in the figures, the blade key has two configurations. The first configuration is employed for the slot adjacent to the edge of the pallet when the key 134 is attached via the horizontal web 136 to the engagement tab 138 received in the receiving slot 130 in the box. This allows stacking of boxes at the edge of the pallet with key slots displaced from the outer circumference of the pallet deck. The box squeezes the web to ensure that the key remains engaged in the slot. The second configuration of the key is used for an inner slot on the pallet and employs an extended tab 140 mounted on the key that joins the receiving slots of two adjacent boxes. The pallets and containers then provide a complete shipping system with an integral connection to provide a rigid structure while preventing cargo fluctuations or slippage.

The blade keys are removable to allow the use of pallets with flat surfaces and volume reduction in stacked assembled or folded pallets, if desired. Alternatively, for pallet shipment, the inner key is in place in the inner key slot of the first pallet with the second pallet deck reversed for stacking while accepting the keys in their respective key slots to join the two decks.

The invention has been described in detail so far as required by patent legislation, and those skilled in the art will recognize modifications or substitutions to the specific embodiments disclosed herein. Such changes are within the scope and spirit of the invention as defined in the following claims.

Claims (17)

A generally flat deck (12), A plurality of stiffeners 14 detachably attached to the bottom of the deck, the at least one stiffener having a plurality of stiffeners 14 having integral means for restricting a pallet strap located in the vicinity of at least one end of the stiffener, A folding shipping pallet comprising means for attaching a plurality of stiffeners to a deck. The method of claim 1 wherein the deck incorporates a second plurality of shoulder holes 22 located in the deck and arranged in a linear spaced apart relationship at predetermined stiffener attachment points, wherein the means for attaching the plurality of stiffeners comprises: A third plurality of elastic slot pins 24 extending from the upper edge of each stiffener, each pin having a third plurality of elastic slots having shanks 40 and expansion heads 44 at the ends of the upper edge of the stiffeners; Pin 24, A plurality of generally cylindrical collars 36 of the same number as the second plurality, each collar having a body inserted into each shoulder hole and a flange 38 extending from the body while engaging the shoulders of each shoulder hole, Each collar further has a through bore, the bore having a first diameter portion sized to receive the shank of each pin and a second diameter portion forming a step, the second diameter portion engaging the head to press the pin into the bore. A collapsible shipping pallet comprising a plurality of generally cylindrical collars 36 which receive the head of the pin by a stepped portion. 4. The fourth plurality of slats (16) according to claim 1, wherein the fourth plurality of slats (16), each slat extends perpendicular to the reinforcement and is detachably attached to the lower edge of each reinforcement; A folding shipping pallet further comprising means for attaching the slats to the reinforcement. 4. The slat of claim 3, wherein each slat has a plurality of shoulder holes 54, Means for attaching the slats to the reinforcement, A fourth plurality of elastic slot fins 52, wherein one pin is suspended from each reinforcement to engage each slat, each pin having a shank and an expansion head at the distal end of the reinforcement. Pin 52, A plurality of generally cylindrical collars 60, each collar having a body inserted into each shoulder hole in the slat and a flange 38 extending from the body while engaging the shoulders of each hole, each collar penetrating therethrough. Further having a bore, the bore having a first diameter portion sized to receive the shank of each pin and a second diameter portion forming a step portion, the second diameter portion being joined by a step portion engaging the head to press the pin into the bore. A folding shipping pallet comprising a plurality of generally cylindrical collars 60 for receiving the heads of the pins. The method of claim 1, wherein the limiting means is Jaws pairs 78 and 80 having generally triangular cross-sections, wherein the jaws are branched between the vertex and the base, and the jaws pair is received in a triangular cutout 82 in the end of the at least one stiffener, the end of which passes through a pallet strap. Jaw pair further having a slot 88 extending through the first sidewall of the end to the apex of the cut so that it extends through, the pallet strap further extends through a branch in the jaws and frictionally presses the jaws to a triangular cutout under tension. Folding shipping pallets containing (78, 80). The folding shipping pallet of claim 5, wherein the triangular cutout abuts the limiting portion 90 at the apex end and the limiting portion engages the base of the jaw pair to prevent translational movement spaced apart from the cutout vertex. 6. The folding shipping pallet of claim 5 wherein the first element of the jaw pair incorporates a hinge tab (94) received in a hinge cutout (96) in the second element of the jaw pair to prevent separation of the jaw pair. The method of claim 5, wherein the at least one reinforcement further comprises a hole 100 in the second sidewall perpendicular to the first sidewall, the hole 100 being located near the base of the triangular cutout and on the rotation of the crank. A collapsible shipping pallet further comprising a crank having a slot shaft 106 received through a mating aperture of the pallet strap for tensioning. 4. The folding shipping pallet of claim 3, wherein each reinforcement further incorporates a forklift cutout on the bottom edge. The folding shipping pallet of claim 2, wherein a slot in each slot pin extends from the head and extends through the shank of the pin to the web. 5. The folding shipping pallet of claim 4, wherein each slat is received in a relief on the bottom surface of the stiffener and the pin is suspended from the top surface of each slat relief in the stiffener. The deck of claim 1, wherein the deck incorporates a plurality of key slots 132 positioned in a spaced relation relative to the receiving slots on the stackable container supported on the deck, and the key is for engagement of the receiving slots on the stackable container. A collapsible shipping pallet further comprising a blister key 134 received within a slot. For assembly and use of folding shipping pallets, Providing a generally planar deck incorporating a plurality of shoulder holes located within the deck and arranged in a linear spaced relationship at predetermined stiffener attachment points; Assembling a reinforcement having elastic slot pins extending from the top edge of each reinforcement to the bottom of the deck, each pin having a shank at the top edge end of the reinforcement to the deck by inserting the pin through a hole in the deck. Assembling the reinforcement having an expansion head, Fastening the reinforcement to the deck using a cylindrical collar having a body inserted into each shoulder hole and a flange extending from the body while engaging the shoulder of each hole, each collar further having a through bore, each bore being A first diameter portion sized to receive the shank of the pin and a second diameter portion forming a step portion, the second diameter portion receiving the head of the pin by a step portion engaging the head to press the pin in the bore, Fastening the reinforcement to the deck, wherein the head of the resilient pin is deformed to receive the bore of the collar and expands to engage the shoulder. The method of claim 13, Assembling the slats to the reinforcement, each slat extends perpendicular to the reinforcement and is detachably received within the relief on the lower edge of each reinforcement, each slat further having a plurality of shoulder holes to receive the elastic slot pins. Assembling the slats to the reinforcement, one pin suspended from the top surface of each slat relief in each reinforcement, each pin having a shank and an expansion head at the distal end of the upper surface of the relief; Fastening the reinforcement to the deck using a cylindrical collar having a body inserted into each shoulder hole and a flange extending from the body while engaging the shoulder of each hole, each collar further having a through bore, each bore being A first diameter portion sized to receive the shank of the pin and a second diameter portion forming the step portion, the second diameter portion receiving the head of the pin by a stepped portion coupled to the head to press the pin into the bore and being elastic And fastening the reinforcement to the deck, wherein the head of the pin is deformed to be received by the bore of the collar and expands to engage the shoulder. 14. The method of claim 13, wherein a jaw pair having a generally triangular cross section is inserted into a triangular cutout 82 in an end of the at least one stiffener, the jaws branching between a vertex and a base, the end being passed through a pallet strap. And inserting a jaw pair further having a slot (88) extending through the first sidewall of the end to the vertex of the cutout so as to extend. The method of claim 14, Loading the shipped material onto the deck, Routing the pallet straps onto the shipped material, Inserting a crank with a slot shaft through a hole in the second sidewall perpendicular to the first sidewall, the hole being positioned near the base of the triangular cutout in the at least one stiffener for engagement of the pallet strap. Inserting, Inserting the strap through a slot in the reinforcement first sidewall and through a branch in the jaw into a slot on the crank, Tensioning the strap by rotating the crank, the strap under tension further comprising tensioning the strap to frictionally press the jaws into the triangle cutout to lock the strap against release of tension on the crank. Method of use and assembly. The system of claim 13, wherein the deck incorporates a plurality of key slots, Inserting the blade key into the key slot, A method for use and assembly of a foldable shipping pallet further comprising the step of stacking a magnetically stacked container having a receiving slot on the bottom surface on the deck by a blade key coupled by the receiving slot.

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